CORE COMPETENCY REQUIREMENTS NIMS CERTIFIED CNC SET UP PROGRAMMER MILLING AND TURNING

Transcription

1 CORE COMPETENCY REQUIREMENTS NIMS CERTIFIED CNC SET UP PROGRAMMER MILLING AND TURNING APPRENTICE CORE COMPETENCIES 1. Identify and Demonstrate Usage of Machine Safety and Personal Protective Equipment 2. Demonstrate Compliance with Lock out / Tag out Procedures and OSHA Requirements and Guidelines 3. Machine Operations and Material Handling, Hazardous Materials Handling and Storage, including EPA, Hazmat, and OSHA 4. Part Inspection 5. Perform the Inspection of Parts 6. Process Control 7. Process Adjustment Single Part Production 8. Participation in Processes Improvement 9. Manual Operations: Layout 10. Manual Operations: Benchwork 11. Sawing 12. Job Process Planning NIMS CREDENTIALS Measurement, Materials, and Safety Level I Job Planning, Benchwork, and Layout Level I 13. Drilling Operations Drill Press Skills Level I 14. Milling: Square Up a Block 15. Manual Milling: Vertical and Horizontal 16. CNC Programming Milling 17. CNC: Write a Simple CNC Milling Program and Review Tool Path 18. CNC: Operate a CNC Milling Machine Milling Level I CNC Milling Level I 19. CNC: Operate a CNC Milling Machine or CNC Machining Center CNC Milling Level II 20. CNC: Advanced Manual Programming 21. Use Manufacturing Modeling Software to Create Milling Programs CNC Milling Level III 22. Turning Operations: Turning Between Centers Turning Between Centers Level I 23. Turning Operations: Chucking Chucking Level I 24. CNC Programming Turning 25. CNC: Write a Simple CNC Turning Program and Review Tool Path 26. CNC: Operate a CNC Lathe CNC Turning Level I 27. CNC: Operate a CNC Lathe or Turning Center CNC Turning Level II 28. CNC: Advanced Manual Programming 29. Use Manufacturing Modeling Software to Create Turning Programs 30. General Housekeeping & Maintenance 31. Preventative Maintenance Machine Tools 32. Tooling Maintenance CNC Turning Level III Included in all Machining Credentials *NOTE: There is not a specific sequence to the implementation of the Core Competencies. The thirty two Core Competencies and twelve NIMS Credentials, listed above, must be satisfactorily completed to meet the requirements of a NIMS Certified CNC Setup Programmer Milling and Turning Apprenticeship Program and earn a Certificate of Completion of Apprenticeship. 22nd of JUNE 2005 NIMS CERTIFIED CNC SETUP PROGRAMMER MILLING AND TURNING CORE COMPETENCY REQUIREMENTS DEVELOPED BY THE NIMS APPRENTICESHIP COMMITTEE

2 WORK PROCESSES SCHEDULE/RELATED INSTRUCTION OUTLINES CNC SET UP PROGRAMMER MILLING AND TURNING NIMS CREDENTIAL: Level I Machining Skills, Measurement, Materials & Safety 1. Identify and Demonstrate Use of Machine Safety and Personal Protective Equipment NIMS Duty & Performance Standard Duty: Carry out assigned responsibilities while adhering to safe practices in accordance with Occupational Safety and Health Administration (OSHA) requirements and guidelines. Document safety activities as required. Include appropriate personal protective equipment. Performance Standard: Given written and verbal safety instructions and checklists based on OSHA requirements and guidelines, demonstrate safe workplace practices in material handling, machine operations, handling of tooling, and handling and application of coolants, cutting fluids and lubricants. Orally explain the actions taken which directly or indirectly bear upon safe practice in the execution of assigned duties. a. Identify areas in plant that require hearing devices and safety glasses. b. Identify proper clothing required on the job to include shoes, gloves, sleeve and pant length, jewelry items, hair length and personal cleanliness. c. Demonstrate OSHA lifting techniques, proper air gun usage and identification, and safe chip handling techniques. d. Identify all pinch points on primary and supportive machine tools and the proper placements of guards. e. Demonstrate both emergency and standard shut down of all required equipment. f. Demonstrate the proper use of hand tools to include hammer, wrenches, screw drivers, punches and pliers. 2

3 2. Demonstrate Compliance with Lock out/tag out Procedures and OSHA Requirements and Guidelines Duty: Carry out assigned responsibilities while adhering to safe practices in accordance with OSHA requirements and guidelines. Document safety activities as required. Performance Standard: Given written and verbal safety instructions and checklists based on OSHA requirements and guidelines, demonstrate safe workplace practices in material handling, machine operations, handling of tooling, and handling and application of coolants, cutting fluids and lubricants. Orally explain the actions taken which directly or indirectly bear upon safe practice in the execution of assigned responsibilities. NOTE Lock out/tag out and right to know will be accounted for in Industrial Safety and Environmental Protection. Material handling here means handling of shafts and overhead cranes, etc., and personal protection. The apprentice should recognize pinch points, cutting points, and control points. 3. Machine Operations and Material Handling, Hazardous Materials Handling and Storage, including EPA, Hazmat, and OSHA Duty: Handle and store hazardous materials as assigned while adhering to safe practices in accordance with OSHA and EPA requirements and guidelines. Document safety activities as required. Performance Standard: Given written and verbal safety instructions detailing the handling and storage of hazardous materials in compliance with OSHA and EPA requirements and guidelines, demonstrate safe workplace practices in the identification, handling, and storage of hazardous materials. 3

4 4. Part Inspection Duty: Develop an inspection plan and inspect simple parts using precision tools and techniques. Prepare reports on the compliance of the parts. Performance Standard: Given the necessary job process sheets for a part and verbal instructions, identify and select the required measuring instruments and conduct the required inspection procedure(s). Complete required written inspection report and make a decision to accept or reject component parts. Provide brief verbal explanation of inspection procedures, results, and decisions. a. Given the necessary job process sheet for a part and verbal instructions, identify and select the required measuring instruments and conduct the required inspection procedures. b. Verify calibrations and sizes of all measuring devices. c. Take measurements to an accuracy of 1/64 for fractions,.002 for decimals and ½ degree for angles. d. Read standard orthographic prints and understand types of lines, title block information, revision levels, abbreviations, symbols, and tolerances. e. Identify surface defects, burrs and any adverse conditions such as flat or torn threads, out of round conditions, eccentricity, etc. 5. Perform the Inspection of Parts Duty: Perform the inspection of parts. Performance Standard: Develop an inspection plan and inspect production parts that will include the use of basic precision measuring tools, optical comparators and profilometers. 4

5 a. Given the necessary job process sheet for a part and verbal instructions, identify and select the required measuring instruments and conduct the required inspection procedures. b. Verify calibrations and sizes of all measuring devices. c. Inspect a part with specified profiles including angles and radius with an optical comparator and describe the compliance of the profiles. d. Read standard orthographic prints and understand types of lines, title block information, revision levels, abbreviations, symbols, and tolerances. e. Using a profilometer, check the finish on a turned part, record the surface finish and compare it to blueprint specifications to determine if it is in compliance. 6. Process Control Duty: Follow a sampling plan. Inspect the samples for the required data. Enter the data on appropriate charts. Graph the data. Respond to the warning conditions indicated by the process charts. Performance Standard: Given the necessary job process sheets for a part, verbal instructions, and the necessary charts and inspection tools, inspect parts according to the sampling plan, collecting the data required for the process control chart. Working with the supplied control and warning limits, place the data, produce new data as needed, graph the data, and take the Stop or Go actions as indicated by the results of producing the process control chart. Provide brief verbal explanation regarding the decision taken. a. Given the necessary job process sheets for a part, verbal instructions and the necessary charts and inspection tools, the apprentice will inspect the parts according to the sampling plan or inspection plan, collecting the data required for the process adhering to the time parameter. Working with the supplied control and warning limits, the apprentice will place the data, produced new data as needed (mean and range), graph the data and take 5

6 Stop or Go actions as indicated by the results of producing the process control chart. The apprentice will provide a brief verbal explanation supporting the decision taken. b. Given a needed capability study and the data collected to satisfy the needs of the capability study, the apprentice will participate as a team member in support of the capability study through an understanding of capability and determining if a calculated Cpk value is acceptable or nonacceptable. With the direction of the team leader, the apprentice will provide all the machining expertise and statistical calculation needed to satisfy the requirements of a capability study (the apprentice is not expected to calculate Cpk values through complex formulas). 7. Process Adjustment Single Part Production Duty: Analyze the performance of a single part production process. Formulate process adjustments or improvements where appropriate. Where appropriate, notify supervision of the proposed adjustment and/or improvement. Where authorized, carry out the strategies for process adjustment and/or improvement. Performance Standard: Given a process plan, part print, inspection process plan, verbal instructions, the necessary tools and equipment, and a part having routine problems being processed, analyze the problem(s), propose a remedy(ies), having been given authorization to implement the process improvement(s), carry it out. Explain the corrective actions and the reasoning used to perform the diagnosis. a. The apprentice will be able to adjust and recalculate speeds and feeds for proper tool life, surface finish, and cycle time optimization. b. The apprentice will be able to inspect a manufactured part. c. The apprentice will be able to edit changes into a CNC milling program. 6

7 8. Participation in Process Improvement Duty: As a member of a process team, analyze the performance of a production process. With the team formulate process adjustments or improvements where appropriate. Where appropriate, notify supervision of the proposed adjustments and/or improvement. Where authorized, carry out the strategies for process adjustment and/or improvement. Performance Standard: Given a process plan, part print, inspection process plan, verbal instructions, the necessary tools and equipment, and a routine production process having a problem(s), as a team member, analyze the problem(s), propose a remedy(ies), having been given authorization to implement the process improvement(s), carry it out. Carry out the cause and effect analysis by participating in the development of the appropriate Q.C. methodology with the team, i.e., fishbone diagram. Explain the Q.C. tool, the corrective actions and the reasoning connecting the root cause analysis to the remedial actions taken. Related Instruction The knowledge and skills the apprentice will need to pass the Level I Machining Skills, Measurement, Materials, and Safety credentialing exam are as follows: Applying the Machinery s Handbook: The apprentice must be able to reference and apply information found in the handbook ok to solve application problems. Referencing thread percentage, finish symbols, and allowances are some of the skills required. Basic Mathematics: The exam will assess basic math knowledge of fraction/decimal conversion, addition and subtraction of decimals, and an understanding of percent. Industrial Safety: The apprentice must become familiar with Hazmat, MSDS, basic personal protective equipment (PPE), and machine tool safety. Apprentice assessment includes identification of a government body that regulates industrial safety Occupational Safety and Health Administration (OSHA). Maintenance: Apprentice assessment includes elementary knowledge of referencing and researching maintenance procedures, hand tool maintenance and safety, and simple tool maintenance. 7

8 Process Adjustment: The exam presents basic problems of machining processes such as tapping, threading, drilling, milling, reaming, and grinding in which a process adjustment functions as the corrective action. Apprentices must identify a basic goal of process improvement. Quality Control Procedures: The exam will evaluate knowledge of basic concepts of SPC and sampling plans. Basic knowledge of inspection plans includes rationale, criteria for choosing the correct measuring instrument, and organization. The evaluation includes basic knowledge of inspection setups and measuring instruments. NIMS CREDENTIAL: Level I Machining Skills, Job Planning, Benchwork, & Layout 9. Manual Operations: Layout Duty: Layout the location of hole centers and surfaces within an accuracy of +/.015 inch. Performance Standard: Given a surface plate, surface gauge, layout height gauge, combination set, scriber, layout ink, prick punch, ball peen hammer, process plan, and part print, lay out hole locations, radii, and surfaces matching the specifications. a. Given instruction/demonstration and reading assignments, the apprentice will demonstrate knowledge and understanding of blueprint reading, and understand orthographic projections in order to perform all machining tasks. b. Given a part print, surface plate and all the required layout tools, the apprentice will select proper tools, and use correct procedure, to lay out a part including the location of hole centers and surfaces within the accuracy of +/.015 inch. 8

9 10. Manual Operations: Benchwork Duty: Using aluminum or mild steel, hand drill and hand tap holes. Use hand drills, hand taps, tap wrench, files, scrapers, and coated abrasives to deburr parts. Use arbor presses to perform press fits. Use bench vises and hand tools appropriately. Performance Standard: Given a process plan, blueprint, and access to hand tools, produce a part with two holes prepared for hand tapping, a hole prepared (reamed) for the press fit of a bushing, and a stud for one of the tapped holes. Deburr the part, hand drill and hand tap the holes, press in the bushing, and install the stud. Given instruction/demonstration and reading assignments, the apprentice will demonstrate knowledge and understanding of blueprint reading, and understand orthographic projections in order to perform all machining tasks. 11. Sawing Duty: Set up and perform sawing to a layout. Choose and mount appropriate blades; weld, break, and re weld blades as necessary. Performance Standard: Given a part with a finished layout and access to an appropriate band saw and blades, finish saw the part to the layout. 9

10 12. Job Process Planning Duty: Develop a process plan for a part requiring milling, drilling, turning, or grinding. Fill out an operation sheet detailing the process plan and required speeds and feeds. Performance Standard: Given a print detailing a part requiring milling, drilling, turning, and grinding, verbal instructions, and appropriate references, formulate a set of strategies to manufacture the part and fill out an operation sheet reflecting the chosen strategies including the required speeds and feeds. Identify all major components and functions of the machine tools, and all major hand tools, measuring tools, tools and fixtures, and work materials. Provide the rationale for the speeds and feeds selected. a. The apprentice will choose the most appropriate location for the origin on the part, and establish a method for defining that location during set up. b. The apprentice will be able to select appropriate work holding devices for various work pieces. c. The apprentice will be able to select appropriate tooling for various operations and materials. d. The apprentice will be able to calculate speeds and feeds for proper toollife and surface finish. Related Instruction The knowledge and skills an apprentice will need to pass the Level I Machining Skills, Job Planning, Benchwork, and Layout credentialing exam are as follows: Basic Mathematics: The exam will assess basic math knowledge from whole number computations and algebra to basic geometry. Application of formulas involving tapping, tapers, speeds and feeds, and threading will be evaluated. Applying the Machinery s Handbook: The apprentice must be able to reference and apply information found in the handbook to solve application problems. Referencing limits, tolerance, and parameters of a material or process are essential skills. Basic Measurement: The exam will test interpretation of basic measuring instruments, resolution, and applicability of basic measuring tools for given situations. Apprentices 10

11 must demonstrate knowledge of the differences and similarities of semi precision and precision measurement. Basic Machining Theory: The apprentice must understand basic types of tooling materials, applications of tooling and processes for drilling, milling, and sawing, turning, and proper procedures using hand tools. A basic understanding of fits and allowances, as well as defining surface finish and machining operation/surface finish relationships, is expected. Layout: The exam will evaluate an understanding of basic and precision layout equipment and procedures. The apprentice should have a basic knowledge of print reading and orthographic projection. Knowledge of the layout of linear, angular, and circular dimensions will be assessed. NIMS CREDENTIAL: Level I Machining Skills, Drill Press Skills 13. Drilling Operations Duty: Set up and operate machine tools to perform routine drilling operations. Performance Standard: Given a semi finished part, process plan, part print, and hand, precision, and cutting tools, as well as access to a drill press and its accessories, produce a part matching the process plan and the blueprint specifications. The part specified will be in the semi finished state, having been squared up and the outer surfaces completed with five center drilled locations. Finishing the part will require the finishing of the five center drilled locations. Each hole must have at least two secondary operations. The secondary operations will consist of reaming, spot facing, countersinking, counter boring, and counter drilling. At least one hole must be a blind hole and one a through hole. At least one hole will be power tapped. a. Given instruction/demonstration and reading assignments, the apprentice will demonstrate knowledge of safety procedures, and the identification of drill press and radial drill press parts and their function. b. Given instruction/demonstration on the proper selection, mounting, set up and usage procedure for necessary work holding devices on the drill press, the apprentice will select, mount, set up, hold, and align work, using work holding devices on the drill press to perform the required drill press operations. 11

12 c. Given instruction/demonstration on the proper selection, mounting, set up and usage procedure for necessary tool holding devices on the drill press, the apprentice will select, mount, set up, and align tool holding devices on the drill press to perform the required drill press operations. d. Given instruction/demonstration, reading assignment, information sheets, and reference charts, the apprentice will calculate cutting speeds and feeds and apply these calculations while performing required machining operations on the drill press. e. Given a drill press, process plan, part print, semi finished part, cutting tools, hand tools, drill press accessories, and instruction/demonstration on the proper set up and procedures used for drilling, tapping, reaming, spot facing, countersinking, and counter boring, the apprentice will perform these secondary operations on the semi finished part within the tolerances specified on the part print. Related Instruction The knowledge and skills an apprentice will need to pass the Level I Machining Skills, Drill Press Skills credentialing exam are as follows: Drill Press Components: Proper operation of a drill press depends on knowledge of drill press components and their functions. Identification of the spindle, base, table, column, variable speed control, and feed handle are essential for safe and effective use of this machine tool. Other essential components are the table lock, column lock, motor, and base. Process Involvement: An important part of any process improvement is an understanding of the symptoms and causes of some common problems associated with drilling operations. Understanding root causes of drill breakage, excessive wear, enlarged diameters, and excessive RPM enable the apprentice to analyze the process and make the correct improvement. Twist Drill Nomenclature and Sizing: Each twist drill is comprised of many separate features. Identifying the web and understanding web thickness enables the apprentice to recognize the effects of excessive web thickness. Knowing the purpose and location of the margin facilitates proper drill diameter measurement as well as the effect of worn margin near the point of the drill. All general purpose drills have the same identical point angle. The included point angle of a drill will vary dependent on the application and the material being machined. Safety Practices: Proper safety procedures insure safe and productive machining. Safety includes safe lifting procedures, hair containment, jewelry removal, and loose clothing containment. Drill press safety includes the proper location of the vise, storage of the chuck key, and chip removal. Safety awareness should be apparent at all times through the correct application of speeds and feeds. 12

13 Countersinking, Counter boring, Spot facing, and Center Drilling: Spot facing, countersinking, and counter boring are drilling procedures used to seat screws and bolts with special head configurations or to seat a fastener or washer evenly on a rough surface. Center drilling is an important procedure for accurate hole location as well as shaft preparation for turning between centers. The specific drilling operations have speeds and feeds that are proportionally slower than drilling with general purpose twist drills. Layout and Inspection: Choosing the correct measuring instrument is primarily dependent on the tolerance range of the specific dimension. Proper set up and correct measuring procedures for each measuring device are critical. The apprentice must also know when and where to apply semi precision and precision layout. Selection and application of proper layout tools and setups are essential in any machining operation. Tapping: The drill diameter used to create a hole for internal threading will dictate the thread percentage or amount of engagement between two mating threaded components. Most tap drill charts for conventional thread forms are based on 70% 75% engagement. Pipe taps used for some pneumatic and fluid connects have tap drills based on other parameters. With the proper equipment, tapping can be performed under power if the drill press is capable of reversing the rotation. Work Holding: The work piece must be held securely to prevent part pullout from the work holding device. The equipment used for work holding parts is dependent upon the shape and size of the part being drilled. Proper location of the vise may prevent the vise from whipping around if the drill gets jammed in the part. Proper selection of work holding devices is critical for safe and accurate application of a drill press. NIMS CREDENTIAL: Level I Machining Skills, Milling: Square up a Block 14. Milling: Square up a Block Duty: Set up and perform squaring up the six surfaces of a block to within +/.002 inch and.002 inch over 4.5 inches squareness. Performance Standard: Given raw material, process plan, part print, and hand, precision, and cutting tools, as well as access to an appropriate milling machine and its accessories, produce a part matching the process plan and the part print specifications. The part will require squaring up from its raw state. 13

14 a. Given instruction/demonstration and reading assignments, the apprentice will demonstrate knowledge of milling machine safety procedures, as well as the identification of milling machine parts and their function. b. Given instruction/demonstration on cutting tool geometry for High Speed Steel milling cutters, the apprentice will perform proper cutting tool selection necessary to perform all required milling operations within the specified tolerances on a part print. c. Given instruction/demonstration on cutting tool geometry and inserted tooling, the apprentice will demonstrate the proper insert and tool holder selection necessary to perform all required milling operations within the specified tolerances on a blueprint. d. Given instruction/demonstration, reading assignment, information sheets, and reference charts, the apprentice will calculate cutting speeds and feeds and apply these calculations while performing required milling operations on the milling machine. e. Given instruction/demonstration on the proper selection, mounting, set up, usage procedure for work holding devices, and an understanding of climb and conventional milling, the apprentice will select, mount, set up, hold, and align work using work holding devices on the milling machine to perform the required milling and squaring operations. f. Given instruction/demonstration on the proper set up and procedures used to perform the squaring up operation, the apprentice will square up six primary surfaces of a raw cut block within the tolerance of ±.002 inch maintaining parallelism and perpendicularity measurement with a TIR of.002 inch over 4.5 inches. Related Instruction The knowledge and skills an apprentice will need to pass Milling: Square up a Block, Level I Machining Skills credentialing exam are as follows: Applying the Machinery s Handbook: The apprentice must be able to reference and to apply information found in the handbook to solve applied problems. Referencing thread percentage, tap drill diameters, speeds, feeds, and cutting tool parameters are some of the skills required. Basic Mathematics: The exam will assess basic math knowledge of fraction/decimal conversion, addition and subtraction of decimals, and an understanding of percentage. Processing basic formulas to solve for the given known or another part of the formula is an additional skill required for this module. 14

15 Vertical Milling Machine Components: The exam presents questions asking the apprentice to identify components of vertical milling machines. Apprentices must be able to identify essential components, their functions, and basic machine adjustments. Threads and Tapping: Specific areas of knowledge include an understanding of tap drill charts and thread percentage, tapping lubricants, tap drills for pipe threads, and taps used for specific operations. The apprentice must be able to troubleshoot basic tapping and threading problems. Safety Practices: Areas of knowledge include knowledge of basic safety, cutting tool safety, and basic machine maintenance and housekeeping. Apprentices must know some elementary first aid procedures they can perform on themselves. Milling Operations Set up: The apprentice must know the procedure for adjusting the mill head to be perpendicular to the table (tramming). Other areas of importance include centering various details or shapes and the proper procedure for utilizing centerfinding tools. The importance of layout lines and machining to the lines as well as the application of the sine bar are included within milling operations set up. NIMS CREDENTIALS: Level I Machining Skills, Manual Milling Skills 15. Manual Milling: Vertical and Horizontal, Level I Machining Skills Duty: Vertical Milling Set up and operate vertical milling machines. Perform routine milling and location of hole centers within +/.005 inch. Performance Standard: Vertical Milling Given raw material, process plan, print, and hand, precision, and cutting tools, as well as access to an appropriate vertical milling machine and its accessories, produce a part matching the process plan and the blueprint specifications using appropriate trade techniques and speeds and feeds. The part specified should require squaring up from the raw state, have at least one milled slot, require the location of at least two drilled and reamed holes within +/.005 inch, and have three steps controlled by tolerances of +/.005 inch. 15

16 a. Given instruction/demonstration and reading assignments, the apprentice will demonstrate knowledge of milling machine safety procedures, and the identification of milling machine parts and their function. b. Given instruction/demonstration on cutting tool geometry for High Speed Steel milling cutters, the apprentice will perform proper cutting tool selection necessary to perform all required milling operations within the specified tolerances on a part print. c. Given instruction/demonstration on cutting tool geometry and inserted tooling, the apprentice will demonstrate the proper insert and tool holder selection, necessary to perform all required milling operations within the specified tolerances on a blueprint. d. Given instruction/demonstration, reading assignment, information sheets, and reference charts, the apprentice will calculate cutting speeds and feeds and apply these calculations while performing required milling, drilling, and boring operations on the milling machine. e. Given instruction/demonstration on the proper selection, mounting, set up, usage procedure for work holding devices, and an understanding of climb and conventional milling, the apprentice will select, mount, set up, hold, and align work using work holding devices on the milling machine to perform the required milling and squaring operations. f. Given required hand and precision tools, instruction/demonstration on the proper set up and procedures used to perform tramming operations on the vertical milling machine, and the process used to indicate a vise, the apprentice will adjust the milling machine head perpendicular to the table within +/.001 inch, and indicate a vise maintaining parallelism and perpendicularity measurement of.002 inch over 4.5 inches. g. Given instruction/demonstration on the proper set up and procedures used to perform the squaring up operation, the apprentice will square up six primary surfaces of a raw cut block within the tolerance of ±.002 inch maintaining parallelism and perpendicularity measurement with a TIR of.002 inch over 4.5 inches. h. Given raw material, process plan, print, and hand, precision, and cutting tools, as well as access to an appropriate vertical milling machine and its accessories, produce a part matching the process plan and the blueprint specifications using appropriate trade techniques and speeds and feeds. The part specified should require squaring up from the raw state, have at least one milled slot, require the location of at least two drilled and reamed 16

17 holes within +/.005 inch, and have three steps controlled by tolerances of +/.005 inch. i. Given raw material, process plan, part print, and hand, precision, and cutting tools, as well as access to an appropriate milling machine and its accessories, produce three bores to specification. The holes will be between ¾ inch and 1½ inches and their locations are to be held within +/.001 inch and diameters within +/.0005 inch. One hole is to be counter bored to a decimal depth holding within +/.002 inch and counter bore diameter within +/.005 inch. j. Given raw material, process plan, part print, and hand, precision, and cutting tools, as well as access to an appropriate milling machine and its accessories, produce a part matching the process plan and the part print specifications. The part specified will require the milling of three deepslots two parallel to one another, the third at right angles to the first two. Related Instruction The knowledge and skills an apprentice will need to pass the Manual Milling: Vertical and Horizontal, Level I Machining Skills and Manual Milling: Vertical and Horizontal, Level II Machining Skills credentialing exams are as follows: Applying the Machinery s Handbook: The apprentice must be able to reference and to apply information found in the handbook to solve applied problems. Referencing thread percentage, tap drill diameters, speeds, feeds, and cutting tool parameters are some of the skills required. Basic Mathematics: The exam will assess basic math knowledge of fraction/decimal conversion, addition and subtraction of decimals, and an understanding of percentage. Processing basic formulas to solve for the given known or another part of the formula is an additional skill required for this module. Vertical Milling Machine Components: The exam presents questions asking the apprentice to identify components of vertical milling machines. Apprentices must be able to identify essential components, their functions, and basic machine adjustments. Threads and Tapping: Areas of knowledge include knowledge of basic safety, cutting tool safety, and basic machine maintenance and housekeeping. Apprentices must know some elementary first aid procedures they can perform on themselves. Safety Practices: Areas of knowledge include knowledge of basic safety, cutting tool safety, and basic machine maintenance and housekeeping. Apprentices must know some elementary first aid procedures they can perform on themselves. 17

18 Milling Operations Set up: The apprentice must know the procedure for adjusting the mill head to be perpendicular to the table (tramming). Other areas of importance include centering various details or shapes and the proper procedure for utilizing center finding tools. The importance of layout lines and machining to the lines as well as the application of the sine bar are included within milling operations set up. NIMS CREDENTIAL: Level I CNC Milling 16. CNC Programming Milling Duty: Using the principles of Cartesian coordinates, develop a program for the manufacture of a simple part. Performance Standard: Given a computer and a basic CNC software program, and a blueprint for part comparison, apply the principles of three dimensional coordinate planes in the development of a simple program for the production of the part on a CNC milling machine. a. The apprentice will be able to describe the functions and use of basic G and M codes. b. The apprentice will be able to identify coordinates on a blueprint with respect to an origin. c. The apprentice will be able to implement linear interpolation into a program to cut straight lines between two points. d. The apprentice will be able to implement circular interpolation into a program to cut true arcs and circles, using I & J (arc vector) and R (radium value) methods. e. The apprentice will be able to write a program using the appropriate format for a particular machine control, and work from a process plan to get guidance for sequences, steps, procedures, machining parameters, etc., that will be used. 18

19 17. CNC: Write a Simple CNC Milling Program and Review Tool Path Duty: Using a computer and editor software, write simple CNC programs using M and G codes from the Machinery s Handbook. Simple programs are single plane, cutter centerline, linear and circular interpolation, and single cutter, with no canned cycles as specified on the print. Performance Standard: Given a part print with the tool path shown, and computer with editor software, write a program, including speeds and feeds, to drive an end mill through a continuous path around three sides of a part requiring the development of a linear interpolation tool path as well as circular interpolation. Store the program on computer media. a. The apprentice will be able to describe the functions and use of basic G and M codes. b. The apprentice will be able to identify coordinates on a blueprint with respect to a part. c. The apprentice will be able to calculate and implement speeds and feeds for proper tool life and surface finish. d. The apprentice will be able to implement linear interpolation into a program to cut straight lines between two points. e. The apprentice will be able to implement circular interpolation into a program to cut true arcs and circles, using the I & J or R (radius value) methods. f. The apprentice will be able to write a program using the appropriate format for a particular machine control, and work from a process plan to get guidance for sequences, steps, procedures, machining parameters, etc., that will be used. 19

20 18. CNC: Operate a CNC Milling Machine Duty: Operate a CNC Milling Machine Performance Standard: Given a CNC mill, create a qualified CNC program, setup and operate the mill, change tool values as necessary, and replace and qualify tooling as necessary. a. The apprentice will be able to describe the functions and use of basic G and M codes. b. The apprentice will be able to identify coordinates on a blueprint with respect to an origin. c. The apprentice will be able to calculate and implement speeds and feeds for proper tool life and surface finish. d. The apprentice will be able to write a program using the appropriate format for a particular machine control, and work from a process plan to get guidance for sequences, steps, procedures, machining parameters, etc., that will be used. e. The apprentice will be able to install and qualify the required tooling for the program. f. The apprentice will be able to mount, locate, and set the origin of the work piece on a CNC milling machine. g. The apprentice will be able to load a program, create a CNC link, or enter a program via control keyboard into a CNC milling machine control. h. The apprentice will be able to safely execute a program for its first run (debugging). 20

21 NIMS CREDENTIAL: Level II CNC Milling 19. Operate CNC Mill or CNC Milling Centers Duty: Set up and operate a CNC Mill or CNC milling center. Performance Standard: Set up the tooling and work piece. Qualify the work piece to the control. Prepare tools or load tools into tool magazine as required, qualify the tools to the control with respect to the work, match their identity to the program. Establish initial tool values or offsets. The part specified should have at least two steps with +/.001 tolerances, one UNC tapped hole, an arc/tangent surface, and require the use of at least one "canned cycle" available on the machine control. a. The apprentice will be able to describe the functions and use of basic G and M codes and other program commands. b. The apprentice will be able to mount, locate and set the part origin of the work piece on a CNC milling center. c. The apprentice will be able to install and qualify the required tooling for the program. d. The apprentice will be able to load a program, create a CNC link, or enter a program via control keyboard into a CNC milling machine control. NIMS CREDENTIAL: Level III CNC Milling 20. CNC: Advanced Manual Programming Duty: Using a computer and editor write sophisticated RS 274 D programs. Sophisticated programs will contain various combinations of change of plane, canned cycles, will employ multiple tools, cutter offsets, linear, circular and 21

22 helical interpolation as well as requiring the matching of surfaces along lines and points of tangency in 3 axes. Store the results on computer media. Performance Standard: Given a blueprint and a process plan, write a program to drive a collection of tooling through the tool paths needed to produce the part shown on the blueprint. The program will require change of tools, change of planes, use of "canned cycles", and tool offsets. Use a computer to write and store the program. a. The apprentice will be able to identify coordinates with respect to an origin. b. The apprentice will be able to calculate and implement speeds and feeds for proper tool life and surface finish. c. The apprentice will be able to write a program using the appropriate format for a particular machine control, and work from a process plan to get guidance for sequences, steps, procedures, machining parameters, etc., that will be used. d. The apprentice will be able to implement circular interpolation into a program to cut true arcs and circles, using the I & J (arc vector), and R (radius value) methods. e. The apprentice will be able to implement automatic cutter radius compensation. f. The apprentice will be able to change and perform machining on different work planes. g. The apprentice will be able to program helical interpolation. h. The apprentice will be able to form and solve triangular constructions on a blueprint to find missing coordinates. 21. Use Manufacturing Modeling Software to Create CNC Milling Programs Duty: Create programs using a manufacturing modeling software package. Performance Standard: Given a blueprint, use a graphics based software package to develop a program to drive a collection of tooling through the tool paths needed to produce the part shown on the blueprint. The program will 22

23 require change of tools, change of planes, use of "canned cycles," and tool offsets. a. The apprentice will be able to identify coordinates with respect to an origin. b. The apprentice will be able to calculate and implement speeds and feeds for proper tool life and surface finish. c. The apprentice will be able to identify and use menus and icons used in the software package. d. The apprentice will be able to draw basic geometric shapes and constructions. e. The apprentice will be able to edit basic geometric shapes and constructions. f. The apprentice will be able to create tool paths for contour milling, pocketing, drilling and tapping. g. The apprentice will be able to post process tool paths into programs. NIMS CREDENTIALS: Level I Turning Operations, Turning Between Centers 22. Turning Operations: Turning Between Centers, Level I Machining Skills Duty: Set up and carry out between centers turning operations for straight turning. Performance Standard: Given raw material, process plan, part print, and hand, precision, and cutting tools, as well as access to an appropriate turning machine and its accessories, produce a part matching the process plan and the part print specifications using appropriate trade techniques and speeds and feeds. The part specified should have at least three diameters within +/.002 inch, one UNC external thread, one UNF external thread, and require an end for end swap. 23

24 a. Given instruction/demonstration and reading assignments, the apprentice will demonstrate knowledge of engine lathe safety procedures, and the identification of engine lathe parts and their function. b. Given instruction/demonstration by a qualified individual on cutting tool geometry and the proper procedure used for grinding lathe tool bits on the off hand grinder, the apprentice will perform grinding operations and produce all the required tool bits necessary to perform all required turning operations within the specified tolerances on a part print. c. Given instruction/demonstration on cutting tool geometry and inserted tooling, the apprentice will demonstrate the proper insert and tool holder selection, necessary to perform all required turning operations within the specified tolerances on a blueprint. d. Given instruction/demonstration, reading assignment, information sheets, and reference charts, the apprentice will calculate cutting speeds and feeds and apply these calculations while performing required various turning operations on the engine lathe. e. Given instruction/demonstration on the proper selection, mounting, set up, and usage procedure for the four specified work holding devices (3 jaw chuck, 4 jaw chuck, face plate and dog, and draw in collet chuck), the apprentice will select, mount, set up, hold, and align work using work holding devices on the engine lathe to perform the required turning operations. f. Given instruction/demonstration on the proper set up and procedures used for drilling and center drilling on the engine lathe, the apprentice will perform drilling and center drilling operations within the tolerances specified on a part print. g. Given instruction/demonstration on the proper procedure used for turning, facing, necking, and grooving operations on the engine lathe, the apprentice will perform turning, facing, necking, and grooving operations within the specified tolerances on the part print. h. Given instruction/demonstration on the proper procedure used for performing shouldering operations on the engine lathe, the apprentice will perform square, angular, and filleted shouldering operations within the tolerances specified on a part print. i. Given instruction/demonstration on the proper set up procedure used for knurling on the engine lathe, the apprentice will set up the machine and perform knurling operations within the tolerances specified on the part print. 24

25 j. Given instruction/demonstration on Unified National Thread nomenclature, formulas and the proper set up procedure used for cutting threads on the engine lathe, the apprentice will cut an external U.N. thread within the tolerances specified on the part print. k. Given a blueprint, instruction/demonstration on taper calculations, and the proper set up procedure used for cutting internal and external tapers on the engine lathe, the apprentice will cut a taper on the engine lathe using the tailstock set over method, compound rest, and a taper attachment to within the tolerances specified on a part print. Related Instruction The knowledge and skills an apprentice will need to pass the Turning Operations: Turning Between Centers, Level I Machining Skills credentialing exam are as follows: Process Improvement and Troubleshooting: To improve a process, one must first understand the process. A competent apprentice should be able to identify the root cause if a straight cut between centers measures as a taper. Measuring a taper (when a straight cut is intended) and moving the tailstock the proper amount based on the measurement is another skill needed to effectively and efficiently engage in turning operations. Other skill sets include the proper way to take the first cut on cast iron and hot roll steel, the root cause of lathe center run out, properly turning hard, material and the effect of having the lathe tool above or below center. Turning Safety: Safety knowledge and practice is an important component for lathe operations. The apprentice must know the basic personal protective equipment needed to operate a lathe safely and effectively. Proper lifting techniques, learning how to find MSDS and HMIS information and some basic personal first aid are essential knowledge for all apprentices. Other safety components involve the safe installation of chucks and collets as well as chip control and chip removal. Lathe Controls: An understanding of basic lathe control mechanisms enables the apprentice to utilize the lathe in an efficient and productive manner. Knowing how each control works and its function is critical to any safe turning operation. Knowing how to use the feed reverse lever, half nut lever and the proper method to change speeds and feeds is also critical knowledge. Each manufacturer of lathes has unique methods of implementing lathe controls. It is the job of the apprentice to become familiar with each particular set of lathe controls. Single Point Threading: Single point threading is one of the fundamental skill sets needed to operate a lathe. The apprentice must be familiar with thread angles, helix angles, thread pitch diameter, lead and different families of thread forms. Proper alignments of the threading tool, as well as the proper location of the compound rest are essential setup steps needed to turn threads with a single point tool. An apprentice must be able to calculate the proper indeed to prevent the thread from either being too deep or too shallow. 25

26 Tapping, Fits, and Allowances: The turning process is often used to size shafts and holes for certain fits. Knowledge of the definitions of a fit and an allowance is essential prior to machining. The apprentice should have a basic knowledge of the types of fits and be able to reference the Machinery s Handbook to determine the size of each component. Planning the sequence of operations is essential to prevent ruining a fit due to burrs and poor surface finish. Measurement: The best choice depends on the accuracy and reliability of the measuring instrument. Tolerance as well as the application will also be important factors. An apprentice must also know how to read the measuring instrument properly. An example would be comparing a depth micrometer, outside micrometer, and a dial indicator. Thread measurement and surface finish are also important factors when measuring features produced by the turning process. Process Control: Monitoring the process with process control techniques results in quality parts and customer satisfaction. The first step in any process control endeavor is, knowing when the part is accepted or rejected. Basic knowledge of process control techniques such as inspection sheets, Pareto charts, capability studies, and X bar/r charts are an effective means of process control. The most common method of process control, besides the inspection sheet, is SPC (statistical process control) utilizing the X bar/r chart. The apprentice must understand the definition of range, mean, upper control limit, lower control limit, and sample size. Tooling and Lathe Set up: Many lathe applications use tooling with carbide inserts. However, some lathe applications use high speed steel tools that must be ground to the desired shape. The apprentice should know the proper sequence for grinding the surfaces of the lathe tool by applying the proper rake angles. Knowledge of the various methods of aligning the lathe centers and the degree of accuracy of each method depends on the tolerance of the work piece dimensions. Proper setups for facing and compound rest fundamentals are other essential skill sets included in this area. Layout Procedures: Layout is the initial step in any machining process. Understanding the concepts and proper utilization of semi precision and precision layout techniques is important for every apprentice. The apprentice should know the function of a scriber and the types of layout instruments used with surface plates. 26

27 NIMS Credentials: Level I Machining Skills, Turning Operations: Chucking 23. Turning Operations: Chucking: Level I Machining Skills S Duty: Set up and carry out chucking operations for turning. Standard: Given raw material, process plan, part print, and hand, precision, and cutting tools, as well as access to an appropriate turning machine and its accessories, produce a part matching the process plan and the print specifications using appropriate trade techniques and speeds and feeds. The part specified should have at least three diameters within +/.005 inch, two bores within +/.005 inch, one UNC external thread, and requires at least two chucking or other work holding set up. a. Given instruction/demonstration and reading assignments, the apprentice will demonstrate knowledge of engine lathe safety procedures, and the identification of engine lathe parts and their function. b. Given instruction/demonstration on cutting tool geometry and the proper procedure used for grinding lathe tool bits on the off hand grinder by a qualified individual, the apprentice will perform grinding operations and produce all the required tool bits necessary to perform all required turning and boring operations within the specified tolerances on a part print. c. Given instruction/demonstration on cutting tool geometry and inserted tooling, the apprentice will demonstrate the proper insert and tool holder selection necessary to perform all required turning, and boring operations within the specified tolerances on a part print. d. Given instruction/demonstration, reading assignment, information sheets, and reference charts, the apprentice will calculate cutting speeds and feeds and apply these calculations while performing various required turning operations on the engine lathe. e. Given instruction/demonstration on the proper selection, mounting, set up, and usage procedure for the four specified work holding devices (3 jaw chuck, 4 jaw chuck, face plate and dog, and draw in collet chuck), the apprentice will select, mount, set up, hold, and align work using work holding devices on the engine lathe to perform the required turning operations. 27

28 f. Given instruction/demonstration on the proper set up and procedures used for drilling and center drilling on the engine lathe, the apprentice will perform drilling and center drilling operations within the tolerances specified on a part print. g. Given instruction/demonstration on the proper procedure used for turning, facing, necking, and grooving operations on the engine lathe, the apprentice will perform turning, facing, necking, boring, and grooving operations within the specified tolerances on the part print. h. Given instruction/demonstration on the proper procedure used for performing shouldering operations on the engine lathe, the apprentice will perform square, angular, and filleted shouldering operations within the tolerances specified on a part print. i. Given instruction/demonstration on Unified National Thread nomenclature, formulas, and the proper set up procedure used for cutting threads on the engine lathe, the apprentice will cut an external and internal U.N. thread within the tolerances specified on the part print. j. Given a blueprint, instruction/demonstration on taper calculations, and the proper set up procedure used for cutting tapers on the engine lathe, the apprentice will cut an external and internal taper on the engine lathe using the tailstock set over method, compound rest, and a taper attachment to within the tolerances specified on a part print. Related Instruction The knowledge and skills an apprentice will need to pass the Turning Operations: Chucking, Level I Machining Skills credentialing exam are as follows: Process Improvement and Troubleshooting: To improve a process, one must first understand the process. A competent apprentice should be able to identify the root cause if a straight cut between centers measures as a taper. Measuring a taper (when a straight cut is intended) and moving the tailstock the proper amount based on the measurement is another skill needed to effectively and efficiently engage in turning operations. Other skill sets include the proper way to take the first cut on cast iron and hot roll steel, the root cause of lathe center run out, properly turning hard material, and the effect of having the lathe tool above or below center. Turning Safety: Safety knowledge and practice is an important component for lathe operations. The apprentice must know the basic personal protective equipment needed to effectively operate a lathe safely. Proper lifting techniques, learning how to find MSDS and HMIS information and some basic personal first aid are essential knowledge for all apprentices. Other safety components involve the safe installation of chucks and collets as well as chip control and chip removal. 28

29 Lathe Controls: An understanding of basic lathe control mechanisms enables the apprentice to utilize the lathe in an efficient and productive manner. Knowing how each control works and its function is imperative to any safe turning operation. Knowing how to use the feed reverse lever, half nut lever, and the proper method to change speeds and feeds is imperative knowledge. Each manufacturer of lathes has unique methods of implementing lathe controls. It is the job of the apprentice to become familiar with each particular set of lathe controls. Single Point Threading: Single point threading is one of the fundamental skill sets needed to operate a lathe. The apprentice must be familiar with thread angles, helix angles, thread pitch diameter, lead and different families of thread forms. Proper alignments of the threading tool as well as the proper location of the compound rest are essential set up steps needed to turn threads with a single point tool. An apprentice must be able to calculate the proper in feed to prevent the thread from either being cut too deep or too shallow. Tapping, Fits and Allowances: The turning process is often used to size shafts and holes for certain fits. Knowledge of the definitions of a fit and an allowance is essential prior to machining. The apprentice should have a basic knowledge of the types of fits and be able to reference the Machinery s Handbook to determine the size of each component. Planning the sequence of operations is essential to prevent ruining a fit due to burrs and poor surface finish. Measurement: Choosing the proper measuring instrument is an important facet of proper inspection. The best choice is dependent on the accuracy and reliability of the measuring instrument. The tolerance as well as the application will determine the choice. An apprentice must also know how to read the measuring instrument properly. An example would be comparing a depth micrometer, outside micrometer, and a dial indicator. Thread measurement and surface finish are also important factors when measuring features produced by the turning process. Process Control: Monitoring the process with process control techniques results in quality parts and customer satisfaction. The first step in any process control endeavor is, knowing when the part is accepted or rejected. Basic knowledge of process control techniques such as inspection sheets, Pareto charts, capability studies and X bar/r charts are an effective means of process control. The most common method of process control, besides the inspection sheet, is SPC (statistical process control) utilizing the X bar/r chart. The apprentice must understand the definition of range, mean, upper control limit, lower control limit, and sample size. Tooling and Lathe Set up: Many lathe applications use tooling with carbide inserts. However, some lathe applications use high speed steel tools that must be ground to the desired shape. The apprentice should know the proper sequence for grinding the surfaces of the lathe tool by applying the proper rake angles. Knowledge of the various methods of aligning the lathe centers and the degree of accuracy of each method depends on the tolerance of the work piece dimensions. Proper setups for facing and compound rest fundamentals are other essential skill sets included in this area. 29

30 Layout Procedures: Layout is the initial step in any machining process. Understanding the concepts and proper utilization of semi precision and precision layout techniques is important for every apprentice. The apprentice should know the function of a scriber and the types of layout instruments used with surface plates. NIMS CREDENTIAL: Level I CNC Turning 24. CNC Programming Turning Duty: Using the principles of Cartesian coordinates develop a program for the manufacture of a simple part. Performance Standard: Given a computer and a basic CNC software program, and a blueprint for part comparison, apply the principles of two dimensional coordinate planes in the development of a simple program for the production of the part on a CNC lathe or CNC turning center. a. The apprentice will be able to describe the functions and use of basic G and M codes. b. The apprentice will be able to identify coordinates on a blueprint with respect to an origin. c. The apprentice will be able to implement linear interpolation into a program to cut straight lines between two points. d. The apprentice will be able to implement circular interpolation into a program to cut true arcs and circles, using I & J (arc vector) and R (radius value) methods. e. The apprentice will be able to write a program using the appropriate format for a particular machine control, and work from a process plan to get guidance for sequences, steps, procedures, machining parameters, etc., that will be used. 30

31 25. CNC: Write a Simple CNC Turning Program and Review Tool Path Duty: Using a computer and editor software write simple CNC programs using M and G codes from the Machinery s Handbook. Simple programs are single plane, cutter centerline, linear and circular interpolation, and single cutter, with no canned cycles as specified on the print. Performance Standard: Given a part print with the tool path shown, and the computer with editor software; write a program including speeds and feeds, to drive a cutting tool through a continuous path following the geometry of a part requiring the development of a linear interpolation tool path as well as circular interpolation. Store the program on computer media. a. The apprentice will be able to describe the functions and use of basic G and M codes. b. The apprentice will be able to identify coordinates on a blueprint with respect to an origin. c. The apprentice will be able to calculate and implement speeds and feeds for proper tool life and surface finish. d. The apprentice will be able to implement linear interpolation into a program to cut straight lines between two points. e. The apprentice will be able to implement circular interpolation into a program to cut true arcs and circles, using the I & J (arc vector), and R (radius value) methods. f. The apprentice will be able to write a program using the appropriate format for a particular machine control, and work from a process plan to get guidance for sequences, steps, procedures, machining parameters, etc., that will be used. 31

32 26. Level I CNC: Operate a CNC Lathe Duty: Operate a CNC Lathe Performance Standard: Given a CNC lathe create a qualified CNC program, setup and operate the lathe, change tool values as necessary, and replace and qualify tooling as necessary. NIMS CREDENTIAL: Level II CNC Turning 27. Level II CNC: Operate a CNC Lathe Duty: Operate a CNC Lathe Performance Standard: Given a CNC lathe create a qualified CNC program, setup and operate the lathe, change tool values as necessary, replace and qualify tooling as necessary. a. The apprentice will be able to describe the functions and use of basic G and M codes. b. The apprentice will be able to identify coordinates on a blueprint with respect to an origin. c. The apprentice will be able to calculate and implement speeds and feeds for proper tool life and surface finish. d. The apprentice will be able to calculate and implement speeds and feeds for proper tool life and surface finish. e. The apprentice will be able to write a program using the appropriate format for a particular machine control, and work from a process plan to get guidance for sequences, steps, procedures, machining parameters, etc. that will be used. 32

33 f. The apprentice will be able to install and qualify the required tooling for the program. g. The apprentice will be able to mount, locate, and set the origin of the work piece on a CNC lathe. h. The apprentice will be able to load a program, create a CNC link, or enter a program via control keyboard into a CNC lathe control. i. The apprentice will be able to safely execute a program for its first run (debugging). NIMS CREDENTIAL: Level III CNC Turning 28. CNC: Advanced Manual Programming Duty: Using a computer and editor, write sophisticated programs. Sophisticated programs will contain various combinations of change of plane, canned cycles, will employ multiple tools, cutter offsets, linear, circular and helical interpolation as well as requiring the matching of surfaces along lines and points of tangency in 3 axis. All results will be stored on computer media. Performance Standard: Given a blueprint and a process plan, write a program to drive a collection of tooling through the tool paths needed to produce the part shown on the blueprint. The program will require change of tools, change of planes, use of canned cycles, and tool offsets. Use a computer to write and store the program. a. The apprentice will be able to identify coordinates with respect to an origin. b. The apprentice will be able to calculate and implement speeds and feeds for proper tool life and surface finish. c. The apprentice will be able to write a program using the appropriate format for a particular machine control, and work from a process plan to get guidance for sequences, steps, procedures, machining parameters, etc., that will be used. 33

34 d. The apprentice will be able to implement circular interpolation into a program to cut true arcs and circles, using the I & J (arc vector), and R (radius value) methods. e. The apprentice will be able to implement automatic cutter radius compensation. f. The apprentice will be able to change and perform machining on different work planes. g. The apprentice will be able to program helical interpolation. h. The apprentice will be able to form and solve triangular constructions on a blueprint to find missing coordinates. 29. Use Manufacturing Modeling Software to Create CNC Turning Programs DUTY: Create programs using a manufacturing modeling software package. Performance Standard: Given a blueprint, use a graphics based software package to develop a program to drive a collection of tooling through the tool paths needed to produce the part shown on the blueprint. The program will require change of tools, change of planes, use of "canned cycles," and tool offsets. a. The apprentice will be able to identify coordinates with respect to an origin. b. The apprentice will be able to calculate and implement speeds and feeds for proper tool life and surface finish. c. The apprentice will be able to identify and use menus and icons used in the software package. d. The apprentice will be able to draw basic geometric shapes and constructions. e. The apprentice will be able to edit basic geometric shapes and constructions. 34

35 f. The apprentice will be able to create tool paths for contour milling, pocketing, drilling and tapping. g. The apprentice will be able to post process tool paths into programs. CORE COMPETENCIES ALIGNED WITH ALL MACHINING CREDENTIALS 30. General Housekeeping and Maintenance Duty: Keep the duty station clean and safe for work. Keep the tools, workbenches, and manual equipment clean, maintained, and safe for work. Performance Standard: Given maintenance, cleaning, and housekeeping checklists, as well as verbal instructions, clean, maintain, and respond appropriately to safety hazards on all bench work tools and conventional and CNC machine tools. Maintain the cleanliness of the general work area. 31. Preventative Maintenance Machine Tools Duty: Inspect and assess the general condition of an assigned machine tool. Make routine adjustments as necessary and as authorized. Report problems to supervision which are beyond the scope of authority. Carry out daily, weekly, and/or monthly routine upkeep chores cited on checklists for a given machine tool. Performance Standard: Given the preventive maintenance procedures and schedules for a given machine tool, as well as sufficient instruction and experience to recognize maintenance problems, carry out routine maintenance, report problems which are beyond the scope of authority, and fill out the history forms for tracking maintenance. 35

36 32. Tooling Maintenance Duty: Inspect and assess the condition of tooling. Refurbish tooling where appropriate. Refer tooling for repair or regrind where appropriate. Performance Standard: Given samples of tooling in various conditions, diagnose the tooling and take the correct steps to put the tooling back in service. The sample tooling should include turning, milling, and drilling tools. These tools should be both insert tooling as well as conventional tooling. The apprentice must demonstrate the offhand grinding of a drill between the diameter of.125 inch and inch. The offhand regrinding of a turning tool and the correct rotation and replacement of inserts in an insert style milling cutter body must be demonstrated. The apprentice must demonstrate the ability to recognize when a cutter should be referred to a tool and cutter grinder. General Housekeeping and Maintenance Given maintenance, cleaning,and housekeeping checklist as well as verbal instructions, clean, maintain, and respond appropriately to safety hazards on all bench work tools and conventional and CNC machine tools. Maintain the cleanliness of the general work area. Preventative Maintenance Machine Tools Given a specific machine tool, the learner will locate, check, and fill all applicable lubrication reservoirs, check for proper oil pressure, and check that all lubrication points are functioning properly. Check the general condition of the equipment and make routine adjustments as stated in the maintenance schedule. Tooling Maintenance a. Diagnose tooling in various conditions and take the correct steps to put the tooling back in service. b. Perform cutter sharpening operations. c. Understand insert identification nomenclature and index or change inserts. 36